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6.8 Decompression Valve 7. Ignition System 7.1 Ignition Module
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Ignition timing is fixed and cannot be adjusted during repair work.
Since there is no mechanical wear in these systems, ignition timing cannot get out of adjustment.
– Remove the shroud – b 6.2 – Remove the fan housing with
rewind starter – b 8.2
: Pull off the short circuit wire (1).
: Take out the screw (2).
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: Remove the ground wire (3).
: Take out the screw (4).
– Remove the ignition module.
If the ignition lead or spark plug boot is damage, install new parts – b 7.1.4
Reassemble in the reverse sequence.
: On machines with handle and/or carburetor heating, position the wire (1) under the ignition
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: Secure ground wire (2) with screw (3).
: Tighten down screws (3 + 4) moderately.
: Place the ignition lead (1) in the guide (arrow).
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: Rotate the flywheel until its raised edge (arrow) is in line with the ignition module.
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7.1.1 Ignition Timing 7.1.2 Removing and Installing
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: Slide the setting gauge (1) 1111 890 6400 between the arms of the ignition module and the raised edge of the flywheel.
– Press the ignition module against the setting gauge.
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: Tighten down the screws (2) firmly – b 3.5
– Remove the setting gauge and use a feeler gauge to check the air gap. It should be 0.2 mm.
Reassemble all other parts in the reverse sequence.
To test the ignition module, use either the ZAT 4 ignition system tester 5910 850 4503 or the ZAT 3 ignition system tester
5910 850 4520.
The ignition test refers only to a spark test, not to ignition timing.
Using the ZAT 4 ignition tester 5910 850 4503
– Before starting the test, install a new spark plug in the cylinder and tighten it down firmly – b 3.5 : Connect spark plug boot to the
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input terminal (1). Push the tester’s output terminal (3) onto the spark plug.
: Crank the engine quickly with the rewind starter (min. 1,000 rpm) and check spark in the tester’s window (2).
Warning!
The engine may start and accelerate during the test.
If a spark is visible, the ignition system is in order. If no spark is visible in the window (2), check the ignition system with the aid of the troubleshooting chart – b 7.4
Using ZAT 3 ignition tester 5910 850 4520
– Before starting the test, install a new spark plug in the cylinder and tighten it down firmly – b 3.5 : Connect spark plug boot to the
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ZAT 3
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terminal (2).
: Attach ground terminal (1) to the spark plug.
: Use adjusting knob (3) to set spark gap to about 2 mm.
7.1.3 Testing the Ignition Module
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While using the ZAT 3, hold it only by the handle (4) or position it in a safe place. Keep fingers or other parts of your body at least 1 cm away from the spark window (3), high voltage connection (2), ground connection (5) and the ground terminal (1).
Warning!
High voltage – risk of electrocution.
– Crank the engine quickly with the rewind starter (min. 1,000 rpm) and check sparkover in the tester’s window (3).
Warning!
The engine may start and accelerate during the test.
If a spark is visible, the ignition system is in order.
If no spark is visible in the window (3), check the ignition system with the aid of the troubleshooting chart – b 7.4
– Remove the ignition module – b 7.1.2
: Pull the grommet (1) off the high voltage output (2).
: Unscrew the ignition lead (3) from the contact pin and pull it out of
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the high voltage output.
: Remove the grommet and insulating tube (4) from the ignition lead.
: Pull the cover off the spark plug boot.
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: Use suitable pliers to pull the leg spring out of the spark plug boot.
– Unhook the leg spring from the ignition lead.
– Pull the boot off the ignition lead.
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– Cut new ignition lead to a length of 195 mm.
– Use a pointed tool to pierce the center of the ignition lead’s insulation, about 15 mm from the end of the lead.
: Pinch the hook of the leg spring into the center of the lead (arrow).
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7.1.4 Ignition Lead / Spark Plug Boot
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– Coat inside of spark plug boot with PressFluid OH 723.
: Push the ignition lead and leg spring into the spark plug boot.
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: Make sure the leg spring locates properly inside the spark plug boot.
– Fit the cover over the spark plug boot.
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: Use a pointed tool to pierce the center of the other end of the ignition lead.
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– Slip the insulating tube and grommet over the ignition lead.
– Pack the high voltage output with STIHL multipurpose grease – b 16.
Do not use either graphite grease or silicone insulating paste.
– Screw the ignition lead into the ignition module.
– Push the grommet over the high voltage output.
– Install the ignition module – b 7.1.2
– Remove the fan housing with rewind starter – b 8.2
– Block the piston with the locking strip – b 5.4
: Unscrew the flywheel nut (arrow).
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: Mount the puller (1)
1135 890 4500 to the flywheel with screws (2).
: Screw home thrust bolt (3) until
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7.1.5 Flywheel
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– Remove the puller from the flywheel.
: Pull off the flywheel.
Inspect flywheel and magnet poles for cracks or other damage. If you find any damage, install a new
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flywheel.
Degrease crankshaft stub and bore in flywheel hub with standard solvent-based degreasant containing no chlorinated or halogenated hydrocarbons – b 16.
Reassemble in the reverse sequence.
: Make sure that machined key (arrow) engages the slot in the crankshaft.
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– Adjust air gap between ignition module and flywheel – b 7.1.2 Assemble all other parts in the reverse sequence.
– Remove carburetor – b 12.2.1 – Remove the switch shaft –
b 10.1
: Pull the ground wire (1) off the contact spring (2).
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: Carefully pry the contact spring (1) sideways and out of the housing.
Reassemble in the reverse sequence.
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: When installing, make sure the contact spring is under the pin (1) and between the stop lugs
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